Patterned Tufted Articles, Surface Coverings Comprising Same, And Systems And Methods Of Making And Using Same

Abstract

A tufted article (e.g., an artificial turf panel) having a backing and a plurality of tufts extending through the backing. The plurality of tufts are distributed among a plurality of patterned regions. Each patterned region has at least one tuft of the plurality of tufts. The tufts of each patterned region differ from the tufts of at least one other patterned region of the tufted article in at least one of color, pile height, yarn type, or yarn density. At least one patterned region creates a longitudinal discontinuity in the color pattern of the tufted article. The tufted article does not have a seam. Complementary side edges of the tufted articles can be secured together to form at least a portion of the surface covering without the need for cutting or the use of inlay components.

1 . A system comprising:
 at least one tufting machine, each tufting machine of the at least one tufting machine defining a respective tufting zone and comprising a plurality of needles that are configured to deliver yam into a backing to form a plurality of tufts that extend through at least a portion of the backing, the backing having a length along a first axis and a width along a second axis that is perpendicular to the first axis;   at least one tensioning apparatus that is configured to guide the backing through the at least one tufting machine while applying tension to the backing, wherein a first tensioning apparatus of the at least one tensioning apparatus is configured to draw the backing from a backing feed roll so that the backing extends from the backing feed roll to the first tensioning apparatus while the at least one tufting machine delivers yam into the backing; and   at least one controller, wherein each controller of the at least one controller is communicatively coupled with each tufting machine of the at least one tufting machine,   wherein the at least one controller is configured to cause the at least one tufting machine to selectively control delivery of yarn into the backing to produce a plurality of patterned regions.   
     
     
         2 . The system of  claim 1 , further comprising a coating machine that is configured to apply a coating over backstitches of the plurality of tufts after the plurality of tufts have been delivered through the backing. 
     
     
         3 . The system of  claim 2 , wherein the at least one tensioning apparatus is configured to maintain at least one dimension of the backing within a selected tolerance after the coating is applied. 
     
     
         4 . The system of  claim 3 , wherein the at least one dimension of the backing comprises a width. 
     
     
         5 . The system of  claim 3 , wherein the at least one tensioning apparatus is configured to maintain the at least one dimension of the backing within the selected tolerance as the backing is advanced from the at least one tufting machine to the coating machine. 
     
     
         6 . The system of  claim 3 , further comprising the backing feed roll, wherein the backing feed roll is configured to feed the backing to the at least one tufting machine. 
     
     
         7 . The system of  claim 1 , wherein the controller comprises:
 at least one processor; and   a memory in communication with the at least one processor, wherein the memory comprises instructions that, when executed by the at least one processor, cause the at least one processor to cause the at least one tufting machine to form the plurality of patterned regions.   
     
     
         8 . The system of  claim 1 , wherein the at least one tensioning apparatus drives movement of the backing in a serpentine pattern comprising peak sections and valley sections. 
     
     
         9 . The system of  claim 8 , wherein the at least one tufting machine comprises a plurality of tufting machines, wherein each tufting machine of the plurality of tufting machines comprises a gantry, and wherein the peak sections of the serpentine pattern are positioned where the backing passes through the gantry of a respective tufting machine, and wherein the valley sections of the serpentine pattern are positioned where the backing is in between sequential tufting machines of the plurality of tufting machines. 
     
     
         10 . The system of  claim 8 , further comprising a catwalk assembly, wherein respective portions of the catwalk assembly overlie valley sections of the serpentine pattern of the backing. 
     
     
         11 . The system of  claim 1 , wherein each tensioning apparatus of the at least one tensioning apparatus comprises a plurality of pin rollers that are configured to control application of longitudinal tension to the backing. 
     
     
         12 . The system of  claim 11 , wherein the plurality of pin rollers operate independently of one another. 
     
     
         13 . A method comprising:
 drawing a backing from a backing feed roll; and   tufting, by at least one tufting machine, a plurality of tufts through the backing to provide a plurality of tufts distributed among a plurality of patterned regions, wherein each patterned region comprises at least one tuft of the plurality of tufts, wherein the tufts of each patterned region differ from the tufts of at least one other patterned region in at least one of color, pile height, yarn type, or yarn density, and wherein at least one patterned region forms a discontinuity in a color pattern moving along a first axis.   
     
     
         14 . The method of  claim 13 , wherein each tuft of the plurality of tufts has a backstitch, and wherein the method further comprises applying a coating over the backstitches of the plurality of tufts. 
     
     
         15 . The method of  claim 14 , further comprising applying tension to the backing to maintain at least one dimension of the backing within a selected tolerance after the coating is applied. 
     
     
         16 . The method of  claim 15 , wherein the at least one dimension of the backing is maintained within the selected tolerance of the at least dimension both following tufting of the plurality of tufts and after the coating is applied. 
     
     
         17 . The method of  claim 13 , wherein a first tufting machine of the at least one tufting machine comprises a needle bar assembly having a plurality of needles that are independently moveable relative to other needles of the plurality of needles, and wherein tufting the plurality of tufts comprises using a selected number of needles of the first tufting machine to deliver yarn to the backing. 
     
     
         18 . The method of  claim 17 , wherein the selected number of needles is less than a total number of needles of said needle bar assembly of the first tufting machine, and wherein at least one needle of the plurality of needles of said first tufting machine does not deliver yarn to the backing during tufting. 
     
     
         19 . The method of  claim 13 , wherein the backing extends from the backing feed roll to the at least one tufting machine during tufting, by the at least one tufting machine, the plurality of tufts through the backing. 
     
     
         20 . The method of  claim 13 , wherein tufting, by the at least one tufting machine, the plurality of tufts through the backing comprises tufting the plurality of tufts through the backing while the backing extends from the backing feed roll to the at least one tufting machine.